MMC Load-Bearing Structure With Controlled Crack Propagation
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Solution Overview
Problem
The reliability and failure modes of continuous fibre Metal Matrix Composite (MMC) structures are not well-understood for use in commercial aircraft components, which are required to be lightweight, low-cost, and easy to manufacture while withstanding extreme environments and having predictable failure modes.
Innovation Solution
A load-bearing structure with a predefined crack-propagation region and optional crack-termination region, comprising longitudinal reinforcing elements aligned in specific directions, to control crack propagation and ensure predictable failure, using a metal matrix composite material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If continuous fibre MMC materials are used to create lightweight load-bearing components, then weight is reduced and ease of manufacture is improved, but reliability and predictability of failure modes are insufficiently understood
Solution Approach 1:
The structure is segmented into distinct regions with different reinforcing element configurations. The crack propagation region contains only first reinforcing elements aligned with the load path, while other regions contain both first and second reinforcing elements. This segmentation allows controlled crack propagation in a specific zone while maintaining overall structural reliability and predictability.
Solution Approach 2:
Different regions of the structure have different local qualities in terms of reinforcing element distribution. The crack propagation region has a specific local quality (only first reinforcing elements) that differs from other regions (both first and second reinforcing elements). This local quality variation enables controlled crack behavior while maintaining overall structural integrity.
2Reliability
If a predefined crack-propagation region is introduced to control crack propagation, then failure mode predictability is improved, but device complexity increases
Solution Approach 1:
The structure is divided into a crack propagation region and other regions based on reinforcing element distribution. This segmentation creates a predefined path for crack propagation while maintaining relatively simple manufacturing processes, as the different regions can be created through controlled material deposition or assembly during manufacturing.
Data Source
AI summary
A load-bearing structure is disclosed and configured to, during operation of the structure, transfer load from a first part of the structure to a second part of the structure via a load path. The component includes a matrix material, a plurality of longitudinal first reinforcing elements embedded in the matrix material, and a plurality of longitudinal second reinforcing elements embedded in the matrix material. The long axis of each first reinforcing element is substantially aligned with a first direction and the long axis of each second reinforcing element is substantially aligned with a second direction, the second direction being substantially perpendicular to the first direction. The structure has a predefined crack-propagation region configured to control the propagation of a crack in the structure. The crack-propagation region either comprises multiple first reinforcing elements and does not comprise any second reinforcing elements; or comprises multiple second reinforcing elements and does not comprise any first reinforcing elements.